Die Parallelism Monitoring for Real-Time Electrode Punching
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Solution Overview
Problem
Conventional methods for measuring die parallelism in secondary battery electrode plate manufacturing are manual, prone to human error, and cannot provide real-time monitoring, leading to potential damage and quality issues due to degraded parallelism during the punching process.
Innovation Solution
A secondary battery electrode manufacturing apparatus with a distance measurement sensor and parallelism calculation unit that automatically converts sensor output values into distance values to determine die parallelism and calculate punch insert amount, enabling real-time monitoring and correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement of die parallelism is performed by a worker, then measurement can be conducted, but it takes time, has human error, and cannot provide real-time monitoring
Solution Approach 1:
The patent replaces manual mechanical measurement with an optical distance measurement sensor that automatically measures die parallelism. The sensor outputs electrical signals that are converted to distance values, eliminating the need for manual dial gauge insertion and providing automated, real-time measurements without human error or time loss.
Solution Approach 2:
The measurement system performs self-measurement continuously during the punching process. The distance measurement sensor automatically monitors die parallelism without requiring worker intervention, and the system self-calculates parallelism values and punch insert amounts, enabling continuous real-time monitoring.
2Loss of information
If equipment is stopped to perform manual measurement, then parallelism can be measured, but real-time parallelism cannot be known during punching
Solution Approach 1:
The distance measurement sensor operates continuously during the punching process, providing uninterrupted real-time measurement of die parallelism. The measurement action continues without interruption, allowing parallelism monitoring throughout the entire punching operation rather than requiring equipment stoppage.
Solution Approach 2:
The system provides real-time feedback on die parallelism during punching by continuously measuring distance values and calculating parallelism. This feedback mechanism allows immediate detection of parallelism degradation, enabling timely corrective actions while maintaining punching operations.
3Extent of automation
If contact sensor is used during punching, then automatic measurement is possible, but the sensor may be damaged
Solution Approach 1:
The patent introduces a distance measurement sensor that measures parallelism indirectly through distance calculations rather than direct contact with the die. This intermediary measurement approach maintains automated measurement capability while eliminating the mechanical contact that causes sensor damage in conventional systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures accurate and real-time monitoring of die parallelism, preventing damage and maintaining electrode quality by automatically adjusting the punch insert amount, thus improving manufacturing efficiency and reducing human error.
Implementation Method 1
a distance measurement sensor installed in a die and configured to output a sensor output value
Data Source
AI summary
A secondary battery electrode plate manufacturing apparatus includes: a distance measurement sensor installed in a die and configured to output a sensor output value; a parallelism calculation unit configured to convert the sensor output value into a distance value to determine parallelism of the die; and a punch insert amount calculation unit configured to calculate a punch insert amount by using the converted distance value.